Electrical terminal applicator with improved terminal tape feed means

Abstract: An electrical terminal applicator (10) is disclosed for crimping terminals (24) onto wires, with the terminals being secured to a tape (26) in a side-by-side relationship. An applicator ram (14) is drivable in a first path (A) through a working stroke towards, and a return stroke away from, a crimping anvil (22). A crimping die (18, 20) on the applicator ram cooperates with the anvil to crimp a portion of a terminal onto a wire during each working stroke of the ram. A track (32) guides the tape in a second path (B) which intersects the first path of the ram. A tape feeding system (44) includes a shuttle member (70) adapted for linear reciprocal movement alongside the second path of the tape in an advancing stroke towards, and a return stroke away from, the crimping anvil. The shuttle member has at least one tooth (76) for engaging indexing apertures (30) in the tape (26) and incrementally advancing the tape on the advancing stroke of the shuttle member. Fixed stop teeth (80, 82) engage the indexing apertures (30) of the tape (26) to prevent the tape from moving back away from the crimping anvil on the return stroke of the shuttle member. The stroke of the shuttle member is adjustable.

Description: Field of the Invention This invention generally relates to the art of electrical terminal applicators and, particularly, to an improved feeding mechanism for tapes with terminals secured thereto in a side-by-side relationship. Background of the Invention It is now commonly known in the art of crimped electrical terminals to provide many types of crimpable terminals on a continuous tape of thin material such as plastic. The terminals are suitably secured to the tape in a manner such that they can be fed to a crimping apparatus, and the leading terminal of the tape is crimped onto a wire after which it is removed from the tape. The present invention relates to an improved applicator for crimping electrical terminals on such a tape and particularly to an improved tape feeding means. Reference is made to US-A-4 019 362 and to GB-A-2 233 263. A known type of electrical terminal applicator includes an applicator ram drivable by a press ram through a working stroke towards, and a return stroke away from, a crimping anvil. The applicator ram has a first crimping die for cooperation with the anvil to crimp a first portion of an electrical terminal onto an exposed end of a conductive core of an insulated electrical wire during each working stroke of the applicator ram. The applicator ram has a second crimping die for cooperation with the anvil to crimp a second portion of the terminal onto the insulation of the electrical wire during each working stroke of the applicator ram. The second crimping die is adjustable axially of the applicator ram. Plate means are mounted for angular adjustment about an axis on, and extending lengthwise of, the applicator ram. The plate means selectively interpose first projections between the press ram and the applicator ram to adjust the shut height of the first and second dies, and selectively interpose second projections between the applicator ram and the second crimping die to independently adjust the shut height of the second die. In this known terminal applicator, as well as other similar tape-feeding applicators, the applicator ram can be considered as being drivable in a first path through its working stroke, and the terminal tape is fed in a second path which intersects the first path of the applicator ram. Tape feeding means are provided for indexing the tape along the second path to sequentially advance a leading uncrimped terminal on the tape in response to reciprocation of the ram. One type of feeding means includes an oscillating feed link or arm, and the feeding link includes a finger for sequentially advancing the tape in response to oscillatory action of the feed link. Such feeding mechanisms usually are limited to terminal tapes which are fairly rigid, such as of metal material, because the feed finger literally engages the tape and pushes it incrementally toward the crimping dies. Such a feed link/feed finger mechanism is not applicable for use with flexible, thin plastic tapes, because the feed finger pushes on the tape in only one place and would tend to buckle or tear the flexible thin plastic material of the tape. When a terminal applicator is designed for crimping terminals which are carried on these plastic tapes, the tapes typically are fed by means of a rotatable wheel having teeth which engage within a series of slots or indexing apertures positioned lengthwise of the tape. The feeding teeth also may be provided on an endless conveyor-type belt which is trained around a pair of spaced pulley wheels. A problem with toothed wheels or toothed conveyors is that the wheels and pulleys require considerable space within the applicator. Such toothed wheels and/or pulley wheels increase the overall dimensions of the terminal applicator beyond that which is being considered acceptable. In addition, such rotatable wheels do not readily permit changing the feed stroke. In other words, terminals may be spaced along the plastic tape on a given or conventional pitch (e.g., 15,24 mm or 0.6 inches). However, if the terminals are too large to be spaced according to that given pitch, heretofore, the terminals were positioned on the plastic tape on a "double pitch" (i.e., 30,48 mm or 1.2 inches), and the crimp press had to be cycled twice for crimping each individual terminal. This invention is directed to solving the problems identified above and providing a simple terminal applicator having an improved feeding system employing a very low-profile toothed mechanism, the mechanism also being adjustable to vary the feed stroke thereof to accommodate terminal tapes with different pitches between the terminals. Summary of the Invention An object, therefore, of the invention is to provide a new and improved electrical terminal applicator with an improved terminal tape feeding system. In the exemplary embodiment of the invention, an electrical terminal applicator is disclosed for crimping terminals onto wires. The terminals are secured to a tape in a side-by-side relationship. An applicator ram is drivable in a first path through a working stroke towards, and a return stroke away from, a crimping anvil. A crimping die on the applicator ram cooperates with the anvil to crimp a portion of a terminal onto a wire during each working stroke of the ram. Track means are provided for guiding the tape in a second path which intersects the first path of the ram. Generally, feeding means are provided for indexing the tape along the second path to sequentially advance a leading uncrimped terminal on the tape in response to reciprocation of the ram. The invention contemplates an improvement in the feeding means, wherein a shuttle member is provided for linear reciprocal movement alongside the second path of the tape in an advancing stroke towards, and a return stroke away from, the crimping anvil. Generally, engagement means on the shuttle member engage the tape and incrementally advance the tape on the advancing stroke of the shuttle member. Complementary interengaging connecting means are provided between the shuttle member and an oscillating link of the tape feeding means for reciprocating the shuttle member in response to oscillation of the oscillating link. The linearly reciprocal shuttle member provides a very low profile for the feeding means in contrast to the rotatable wheels of the prior art. As disclosed herein, the tape includes a series of indexing apertures lengthwise thereof. The engagement means on the shuttle member is provided by at least one tooth engageable in the indexing apertures of the tape. The tooth has an abrupt leading edge for establishing a driving relationship with the leading edges of the indexing apertures on the advancing stroke of the shuttle member. The tooth has a chamfered trailing edge for riding under the trailing edges of the indexing apertures on the return stroke of the shuttle member. Still further, stop means are provided alongside the second path of the tape for engaging the tape and preventing the tape from moving away from the crimping anvil on the return stroke of the shuttle member. As disclosed herein, the stop means are provided by at least one fixed tooth on the applicator for engagement in the indexing apertures of the tape. The tooth has an abrupt leading edge for stoppingly engaging the leading edges of the indexing apertures, and the tooth has a chamfered trailing edge for riding under the trailing edges of the indexing apertures. At least one such fixed tooth may be located forwardly of the shuttle member, or rearwardly of the shuttle member or both. Brief Description of the Drawings The features of the invention are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: FIGURE 1 is a perspective view of an applicator for crimping electrical terminals to electrical wires, the applicator including the improved terminal tape feed system of the invention; FIGURE 2 is an exploded perspective view of the interior area of the applicator incorporating the terminal tape feeding system and the tape moving means; FIGURE 3 is a somewhat schematic illustration of the shuttle member and stop teeth, with the shuttle member at a forward end of its stroke; FIGURE 4 is a view similar to that of Figure 3, with the shuttle member at the rear end of its stroke; FIGURE 5 is a view similar to that of Figure 4, with the shuttle member shown at the rear end of a stroke which is longer than that of Figures 3 and 4; FIGURE 6 is a somewhat schematic illustration of the terminal crimping means and terminal tape moving means in their inoperative condition; FIGURE 7 is a view similar to that of Figure 6, but with the crimping means in crimped condition and the tape moving means in clamping condition; FIGURE 8 is a view similar to that of Figure 7, with the tape moving means having been moved laterally to break the crimped terminal away from the tape; FIGURES 9 and 10 are somewhat schematic side and front elevational views, respectively, of the applicator ram, crimping die, anvil means and the piston-and-cylinder device isolated from the entirety of the applicator to illustrate the preposition condition of the crimping die in the first portion of the split cycle system; FIGURES 11 and 12 are views similar to Figures 9 and 10, respectively, with the applicator ram and crimping die being moved to a crimping position during the second portion of the split cycle system; FIGURES 13 and 14 are views similar to that of Figures 11 and 12, respectively, with the crimping die being moved away from a crimped terminal during the return stroke of the applicator ram; and FIGURES 15 and 16 are views similar to that of Figures 13 and 14, respectively, with the applicator ram back at the end of its full return stroke and the magnet being disengaged from the crimping die. Detailed Description of the Preferred Embodiment Referring to the drawings in greater detail, and first to Figure 1, an electrical terminal applicator, generally designated 10, includes a frame, generally designated 12, which, in turn, includes an applicator ram housing 12a in which is mounted an applicator ram, generally designated 14, for vertical reciprocating motion within the housing in the direction of double-headed arrow "A". An adaptor head 16 projects upwardly of applicator ram 14 for engagement by a press ram which is not shown in the drawing but which is well known to those skilled in this art. An insulation crimping die 18 projects from the bottom of applicator ram 14, beneath housing 12a, and is juxtaposed with a conductive core crimping die 20 also projecting from the applicator ram beneath housing 12a. Die 18 is positioned forwardly of die 20 when viewed in Figure 1. A crimping anvil means, generally designated 22, including a pair of crimping anvils 22a and 22b (Fig. 2), is located on frame 12 beneath crimping dies 18 and 20. In essence, the crimping dies and the crimping anvil means defines a crimping station of applicator 10. In the general operation of applicator 10, applicator ram 14 is drivable by the press ram along a first path through a working stroke towards, and a return stroke away from, crimping anvil means 22, as indicated by double-headed arrow "A". Crimping dies 18 and 20 cooperate with crimping anvils 22a and 22b, respectively, to crimp an electrical terminal (described hereinafter) onto an electrical wire during each downward working stroke of applicator ram 14. Applicator 10 is designed for seriatim crimping of a plurality of terminals 24 carried by a thin flexible tape 26, such as of plastic material. The terminals may be secured to the tape within integral cylindrical portions 28 of the plastic tape, with the terminals projecting transversely of the longitudinal dimensions of the tape. Actually, the tape has a dual thickness and cylindrical portions 28 are formed in the upper thickness, as shown. The tape has a series of indexing apertures or slots 30 lengthwise thereof. Terminal tape 26 is fed into applicator 10 to a track means, generally designated 32, which guides the tape along a second path which generally perpendicularly intersects the first path of the applicator ram. Referring to Figure 2, the track means includes a platen 34 for supporting the terminal tape, along with a longitudinal plate 36 to sandwich the apertured edge of tape 26 between the plate and the platen. Still referring to Figure 1, a terminal tape feeding linkage, generally designated 44, is assembled between frame 12 and housing 12a and includes a pivot bolt or screw 46, a feed link in the form of a rocker arm 48 and a drive connection including a rod 50 at the bottom of the rocker arm. Pivot bolt or screw 46 is adjustable lengthwise of a slot 52 in a brace portion 54 of frame 12 for purposes described hereinafter. Specifically, the bolt projects outwardly from a yoke 55 through slot 52 and has a locking nut 56 threaded to the distal end thereof. The yoke is free to rotate about the axis of the pivot bolt. The locking nut straddles the slot and bears against the outside of frame 12. The yoke straddles the slot and engages the inside of the frame. Therefore, tightening of the nut effects damping of the frame to fix the position of pivot bolt 46. The yoke has a groove 55a which embraces rocker arm 48 and slides along an edge thereof. Therefore, loosening of nut 56 allows the yoke to slide lengthwise of the rocker arm to change the location of pivot bolt 46 and, thereby, the pivot point of the rocker arm. Rocker arm or feed link 48 is swung about pivot pin 46 by a slidable rod 58 (by means not shown) for effecting feeding of terminal tape 26 along platen 34 in the direction of arrow "B" toward anvil means 22 to locate the leading uncrimped terminal 24 of the tape at the crimping station defined by the crimping dies and anvil means. As is known in the art, when the press ram drives applicator ram 14 downwardly as described above, crimping dies 18 and 20 are effective to crimp the lead terminal on tape 26 onto an electrical wire. The press ram/applicator ram are cycled in unison with the operation of feed link 48 to effect advancement of terminals 24 seriatim to the crimping station. An adjusting plate assembly, generally designated 60, is provided for adjusting the shut heights of crimping die 18 and/or crimping die 20. The adjusting plate assembly includes first and second adjusting plates, generally designated 62 and 64, respectively, mounted for rotation about an axis 66 and include projections of various heights extending in the direction of movement of applicator ram 14. These adjusting plate assemblies are known in the art. Up to this point, the above description of terminal applicator 10 is fairly known in the art of terminal applicators. The invention includes an improved feeding system for terminal tape 26. As will be understood hereinafter, the feeding system of this invention provides a very low profile in contrast to the feeding wheels of the prior art, and the system of this invention affords adjustment of the advancing stroke of the terminal tape to accommodate terminals secured to the tape on different pitches lengthwise thereof. More particularly, referring to Figures 3-5 in conjunction with Figure 2, the tape feeding system of the invention includes a shuttle member 70 adapted for linear reciprocal movement alongside and parallel to the path of terminal tape 26 in an advancing stroke towards, and a return stroke away from, the crimping station at anvil means 22 (Figs. 1 and 2). The direction of the stroke of the shuttle member is shown by double-headed arrow "C" in Figure 3. The shuttle member is shown at the forward end of its advancing stroke in Figure 3 and at the rear end of its return stroke in Figure 4. The shuttle has an upwardly projecting arm 72 provided with a vertically elongated slot 74 for receiving drive rod 50 located at the bottom of feed link 48 (Fig. 1). Drive rod 50 is disposed within slot 74 of shuttle arm 72. In essence, oscillatory pivoting movement of feed link or rocker arm 48 is indicated by double-headed arrow "D" (Fig. 3) which, in turn, effects linear reciprocal movement of shuttle member 70 as indicated by double-headed arrow "C". The drive rod and the slotted shuttle arm provide complementary interengaging connecting means between the shuttle member 70 and the oscillating feed link 48 of the tape feeding means. Generally, engagement means are provided on shuttle member 70 for engaging terminal tape 26 and incrementally advancing the tape on the advancing stroke of the shuttle member. More particularly, the shuttle member has a pair of upwardly projecting teeth 76 which are engageable in the indexing apertures 30 (Fig. 1) of tape 26. The teeth have abrupt vertical leading edges 76a for establishing a driving relationship with the leading edges of the indexing apertures 30 of tape 26 on the forward advancing stroke of the shuttle member. The teeth have chamfered trailing edges 76b for riding under the trailing edges of apertures 30 on the return stroke of the shuttle member. The rear end of the return stroke is shown in Figure 4. The length of the stroke is indicated by arrows "E". Generally, stop means are provided for engaging the terminal tape 26 and preventing the tape from moving backward or away from the crimping station on the return stroke of shuttle member 70. More particularly, a single stop tooth 80 is located generally forwardly or downstream of shuttle member 70, and a pair of stop teeth 82 are located generally rearwardly or upstream of the shuttle member. Teeth 80 and 82 are appropriately fixed relative to the movement of the shuttle member and its teeth 76. Stop tooth 80 has an abrupt vertical leading edge 80a and stop teeth 82 have abrupt vertical leading edges 82a for stoppingly engaging the leading edges of indexing apertures 30 of terminal tape 26 as shuttle member 70 moves backward during its return stroke. Conversely, stop tooth 80 has a chamfered trailing edge 80b, and stop teeth 82 have chamfered trailing edges 82b for riding under the trailing edges of the indexing apertures. In other words, teeth 76, 80 and 82 are all similarly shaped. Therefore, when shuttle member 70 and its teeth 76 incrementally advance the terminal tape toward the crimping station, the tape (along the line of the indexing apertures) ride over the rear chamfered edges 80b and 82b of stop teeth 80 and 82, respectively. When the shuttle member moves in its return stroke, the chamfered trailing edges 76b of the shuttle teeth 76 ride under the trailing edges of the indexing apertures as well as the material between the apertures, while the abrupt leading edges of stop teeth 80 and 82 engage the tape to prevent it from returning with the shuttle member. With the unique feeding means of the invention, as described above, the stroke of shuttle member 70 can easily be adjusted. Specifically, referring to Figure 5, an extended or lengthened stroke is shown by arrows "F", the extended stroke being approximately twice as long as stroke "E" in Figure 4. This adjustment is made by changing the location of the pivot point for rocker arm 48 (i.e., pivot bolt 46) which, in turn, changes the length of the arc in which drive rod 50 oscillates. In other words, comparing Figures 3 and 4 wherein Figure 3 shows the forward limit position of the shuttle and Figure 4 shows the rear limit position of the shuttle for stroke "E", it can be seen that drive rod 50 moves in an arc about point 46, in response to pivoting of rocker arm 48, and oscillates back-and-forth between the bottom of slot 74 and the middle of the slot. Now, comparing Figure 3 with Figure 5, it can be seen that drive rod 50 moves back and forth between the extreme opposite ends of slot 74, as shuttle member 70 moves in twice the stroke as indicated by arrows "F" in Figure 5. In order to double the stroke of shuttle member 70, as described above in relation to Figures 3-5, reference is made back to Figure 1 wherein it can be seen that pivot bolt 46 for rocker arm 48 has the locking nut 56 on the end thereof. The locking nut can be loosened so that the pivot bolt can be moved within elongated slot 52 in brace portion 54 of the applicator frame. The position of the pivot bolt within this slot determines the arcuate length of movement of the bottom of feed link or rocker arm 48 and, thereby, the arcuate movement of the drive connection with shuttle member 70, afforded by drive rod 50 within slot 74 of shuttle arm 72. Thus, by moving pivot bolt 46 upward, the length of the pivoting of arm 48 is increased, which thus increases the stroke of the shuttle member 70. When the desired extent of pivoting of rocker arm 48 is established, nut 56 is tightened to fix the position of pivot bolt 46. Drive rod 50 within slot 74 of shuttle arm 72 establishes a lost motion driving connection between rocker arm 48 and shuttle member 70 in order to convert arcuate movement of rod 50 to horizontal translational movement of shuttle member 70. After a terminal 24 is crimped to a wire, the terminal and wire assembly must be removed from the tape 26 holding the terminals. This is accomplished by a tape moving means for moving the terminal tape 26 relatively away from crimping dies 18 and 20 when the dies are in crimping condition and in engagement with a crimped terminal 24, to break the crimped terminal away from the tape. In the preferred embodiment, applicator 10 employs at least a portion of platen 34 and guide plate 36 as the opposing jaws of a tape clamping means for engaging and gripping opposite surfaces of the tape and pulling the tape laterally of its second path of movement as indicated by arrow "B" (Fig. 1) away from crimping dies 18 and 20 and the crimped terminal. More particularly, referring to Figures 2 and 6 in conjunction with Figure 1, Figure 6 shows an uncrimped terminal 24 supported by anvils 22a and 22b below crimping dies 18 and 20 which are raised or in their non-crimping condition. Tape 26 is shown in Figure 6 with its rear or lateral edge opposite terminals 24 between a portion of platen 34 and a portion of guide plate 36. The tape is free to move along its second path of travel toward the applicator ram/crimping dies. Teeth 76 of shuttle member 70 which define the tape feeding means of the applicator also are seen in Figure 6. Before proceeding to Figure 7, reference is made back to Figure 2 wherein a pair of bolts 86 extend through a pair of countersunk holes 87 in guide plate 36 and are threaded into a pair of internally threaded holes 88, in platen 34. A pair of coil springs 89 surround bolts 86 and, when the bolts are threaded into holes 88, the coil springs are compressed between a pair of washers 89a abutting under the heads 86a of the bolts and the countersunk configuration of holes 87. This allows guide plate 36 to sort of "float" relative to platen 34 and allows the tape to move freely between the guide plate and the platen without binding. The bolts also provide a general pivot area for guide plate 36 when the guide plate is biased downwardly into gripping engagement with the tape as described below. Figure 7 shows applicator ram 14 having been driven downwardly in its working stroke as indicated by arrow "G". Dies 18 and 20 also can be seen having been driven downwardly into a crimping condition, crimping terminal 24 onto an electrical wire, generally designated 90. Actually, as is known in the art, crimping die 18 crimps a portion of the terminal onto the insulation 90a of the wire, and crimping die 20 crimps a portion of the terminal onto a stripped portion of the conductor 90b of the wire. It also can be seen in Figure 7 that applicator ram 14 has engaged an L-shaped lever, generally designated 92, which is pivoted on the applicator frame at 94. A spring, such as a coil spring 96, is sandwiched between lever 92 and guide plate 36. The end of the lever which engages applicator ram 14 is provided with a roller 98 to compensate for lost motion between the vertically linearly reciprocal ram and the arcuately rotatable lever. When lever 92 is driven downwardly by the applicator ram, from the position shown in Figure 6 to the position shown in Figure 7, spring 96 is compressed and biases guide plate 36 toward platen 34 to clamp the rear edge of terminal tape 26 therebetween. The compressed force of spring 96 overcomes the spring load of springs 89 (Fig. 2) to pivot the floating guide plate downwardly. Now, referring to Figure 8, it can be seen that a piston and cylinder device, generally designated 100, includes a piston 102 connected to a movable assembly, generally designated 104, which includes platen 34 and guide plate 36. The assembly is movable in a track 106 of frame 12 (see Fig. 2). The piston and cylinder device is effective to move the platen and guide plate assembly 104 in the direction of arrow "H" (Fig. 8) away from crimping dies 18 and 20 when the dies are in crimping condition and in engagement with a crimped terminal. With tape 26 clamped between platen 34 and guide plate 36, this movement also is effective to move the tape in the direction of arrow "H" and effectively break the crimped terminal away from the tape. In order to further facilitate gripping of the opposite surfaces of tape 26, one or both of the platen 34 and/or the guide plate 36 can be provided with serrations 108 on the clamping surfaces thereof. This is seen best in Figure 2 wherein the serrations are formed by ridges extending parallel to the feeding path of the terminal tape which, in turn, is perpendicular to the pulling direction on the tape as indicated by arrow "H" (Fig. 8). With the platen and guide plate assembly 104 being actuated by a pneumatic device such as piston and cylinder device 100, it is well within the understanding of one skilled in this art that it would be known to cycle the operation of the pneumatic piston and cylinder device with the cycle of operation of the pneumatic press ram which operates applicator ram 14, as is known in the art. After the ram 14 begins to rise from its crimped condition, piston and cylinder device 100 operates to move the movable assembly 104 including the tape 26 and uncrimped terminals 24 back to the position shown in Figure 6. A system for converting an ordinary press and applicator so that it operates like a split cycle press is shown in the somewhat schematic illustrations of Figures 9-16. In those views, applicator ram 14 is shown in conjunction with one of the crimping dies 18 or 20, along with a piston-and-cylinder device, generally designated 110, which includes a piston 112 projecting from the bottom of a cylinder 114, the device being pneumatically operated, such as an air cylinder. The device is mounted to the side of ram housing portion 12a of frame 12 (Fig. 1), and the piston projects through a cross brace 116 on the frame (Figs. 9-16) and is connected at the distal end of the piston, as at 118, to crimping die 18. Anvil means 22 also are shown in Figures 10, 12, 14 and 16, and terminals 24 of terminal tape 26 (Fig. 1) are simply shown by a line or series of circles in these figures. Finally, for purposes to be described in greater detail hereinafter, magnet means in the form of one or more rare earth magnets 120 are mounted on applicator ram 14 for engaging and releaseably retaining a top portion 122 (see Fig. 9, for instance) of crimping die 18. In the alternative, other mechanisms such as a spring loaded latching structure could be utilized to releasably engage and release the crimp die 18. The axis of the piston-and-cylinder device 110 is shown at "X" (Fig. 10). The axis is generally parallel to the working stroke "A" of applicator ram 14. An arm 124 of the crimping die(s) projects laterally outwardly for connection to the distal end of piston 112 at 118. The operation of the system in terminal applicator 10 now will be described. Referring first to Figures 9 and 10, piston 112 can be seen to have moved crimping die 18 downwardly in the direction of arrow "I" where the die has sandwiched an uncrimped terminal 24a between the die and anvil means 22. This is considered the preposition of the crimping die. In other words, the pneumatic piston-and-cylinder device has moved crimping die 18 through a first portion of movement into engagement with an uncrimped terminal to preposition the terminal prior to crimping thereof. This action properly locates the terminal so that an electrical wire can be accurately inserted into the prepositioned terminal, particularly when using an automated machine. The gripping force exerted on the uncrimped terminal 24a by piston 112 through crimping die 18 and anvil means 22 can be changed by adjusting the pressure in cylinder 114. This occurs because the stroke of piston 112 is sufficiently long so that it would completely close the die and anvil if a terminal were not positioned therebetween. Referring to Figures 11 and 12, applicator ram 14 has been driven downwardly in the direction of arrow "J", so that a driving shoulder portion 126 thereof which mounts magnets 120 engages top portion 122 of crimping die 18 and drives the die through a second portion of movement to effect crimping of the prepositioned terminal. The crimped terminal is shown at 24b. In other words, Figures 9 and 10 show the first portion of movement of the crimping die, and Figures 11 and 12 show the second portion of movement of the crimping die, i.e. the split cycle of operation of the die. Figures 13 and 14 show applicator ram 14 and crimping die 18 being moved upwardly or away from anvil means 22. The crimping die is fabricated of highly magnetically attractable material, such as a ferrous metal or the like, and magnets 120 are effective to engage and magnetically "grasp" top portion 122 of crimping die 18 and pull the die upwardly with the applicator ram in the direction of arrow "K". This action forces piston 112 back upwardly into cylinder 114. The applicator ram will pull the crimping die upwardly by means of magnets 120, until a ledge 130 (Figs. 1, 13, 14) on the crimping die abuts against the bottom surface 116a of brace 116 which defines a stop means to limit the upward movement of the crimping die. Referring to Figures 15 and 16, with crimping die 18 being stopped by bottom surface 116a of brace 116, applicator ram 14 continues to move upwardly in the direction of arrow "L", as the magnets are pulled away from the top of the crimping die. The applicator ram now is at the upper limit position of its return stroke. With magnets 120 now being spaced from crimping die 18, piston-and-cylinder device 110 can again drive the crimping die down to its preposition as described above in relation to Figures 9 and 10, to begin the next cycle of operation of the applicator. It should be understood that piston-and-cylinder device 110 could be used to exert an upward force on crimping die 18 to force the die away from its crimped position and back to the beginning of a new cycle of operation. However, it must be understood that these crimping cycles are very short in relative time - the length of a single cycle being on the order of 250 milliseconds. Therefore, it is difficult and/or expensive to properly time the actions of a pneumatic device in such a short period of time. Consequently, magnets 120 are used as a "mechanical latch" which does not depend in any way upon a timing circuit or cycle. A blast of air may be cycled into cylinder 114 simply to assist in breaking the crimping die 18 away from a crimped terminal, but the magnet means is the primary force for lifting and returning the crimping die back to its upper position for the next cycle of operation. This also assists in the event the crimping tooling and terminal jam or bind together as the tooling is supposed to disengage from the terminal. Although the applicator 10, shown in Figures 1-8, is configured for use with tape 26 carrying closed barrel terminals 24, it should be understood that the tape moving system described herein can be utilized with any type of terminal, closed barrel or not, that is carried by tape. The feeding system can be used with any type of terminal, regardless of the type of carrier. Similarly, the system for converting an ordinary press to operate like a split cycle press can operate with any type of closed barrel terminal, regardless of the type of carrier. That is, it can be used with closed barrel terminals that are carried on plastic tape, continuously molded plastic carriers, metal carriers or even loose piece parts delivered in an automated manner. With such other types of carriers, the feeding system and manner of removing the terminals from the carrier would be modified compared to that shown herein, as is known in the art. It will be understood that the invention may be embodied in other specific forms without departing from the scope of the appended claims. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.

Claims: An electrical terminal applicator (10) for crimping terminals (24) onto wires, with the terminals being secured to a tape (26) in a side-by-side relationship, an applicator housing (12a) having a passage therethrough, an applicator ram (14) positioned in said passage and drivable therein in a first linear vertical path (A) through a working stroke towards, and a return stroke away from, a crimping anvil (22), a crimping die (18, 20) mounted on a lower portion of the applicator ram (14) for cooperation with the anvil (22) to crimp a portion of a terminal onto a wire during each working stroke of the ram, an adaptor head (16) on an upper portion of the applicator ram (14) for engagement with a press ram, track means (32) for guiding the tape (26) in a tape path (B) which intersects the ram path (A), feeding means (44) for indexing the tape (26) along the tape path (B) to sequentially advance a leading uncrimped terminal on the tape in response to reciprocation of the ram, characterized in that said tape feeding means (44) comprises a shuttle member (70) which is adapted for linear reciprocal movement (C) alongside the tape path (B) in an advancing stroke towards, and a return stroke away from, the crimping anvil (22), engagement means (76) which is provided on the shuttle member (70) for engaging the tape (26) and incrementally advancing the tape in a downstream direction on the advancing stroke of the shuttle member, and complementary interengaging connecting means (50, 72, 74) which is provided between the shuttle member (70) and an oscillating feed link (48) of the tape feeding means (44) for reciprocating the shuttle member in response to oscillation of the oscillating link. The electrical terminal applicator as set forth in claim 1, including stop means (80, 82) alongside the tape path for engaging the tape (26) and preventing the tape from moving back away from the crimping anvil (22) on the return stroke of the shuttle member (70). The electrical terminal applicator as set forth in claim 1 or 2, wherein said tape (26) includes a series of indexing apertures (30) lengthwise thereof, and wherein said stop means comprise at least one fixed tooth (80, 82) on the applicator and engageable in the indexing apertures (30) of the tape (26). The electrical terminal applicator as set forth in claim 3, wherein said engagement means has at least one tooth (76) with an abrupt leading edge (76a) for establishing a driving relationship with leading edges of the indexing apertures (30) on the advancing stroke of the shuttle member (70), and the tooth (76) has a chamfered trailing edge (76b) for riding under the trailing edges of the indexing apertures (30) on the return stroke of the shuttle member (70). The electrical terminal applicator as set forth in claim 3, wherein said at least one fixed tooth (80, 82) has an abrupt leading edge (80a, 82a) for stoppingly engaging the leading edges of the indexing apertures (30), and the tooth (80, 82) has a chamfered trailing edge (80b, 82b) for riding under the trailing edges of the indexing apertures (30) during the advancing stroke of the shuttle member (70). The electrical terminal applicator as set forth in claim 5, wherein said at least one fixed tooth (80) is located downstream of the shuttle member (70). The electrical terminal applicator as set forth in claim 5, wherein said at least one fixed tooth (82) is located upsteam of the shuttle member (70). The electrical terminal applicator as set forth in claim 5, including a plurality of said fixed teeth (80, 82) located both downstream and upstream of the shuttle member (70). The electrical terminal applicator as set forth in any of claims 1 to 8, including means (56) for adjusting said connecting means (50, 72, 74) between the shuttle member (70) and the oscillating link (48) to change the length of the advancing stroke of the shuttle member (70) without substantially changing the oscillational movememnt of the link (48). The electrical terminal applicator as set forth in any of claims 1 to 9, wherein said shuttle member (70) is movably mounted on frame means (12).

Inventors: MARSHALL ROBERT C, QUINN ROBERT L, MARSHALL, ROBERT C., QUINN, ROBERT L.
Applicants: MOLEX INC, MOLEX INCORPORATED
Application year: 1994
Main classification: H01R43
IPC codes: H01R43